Tube arrangement in a once-through horizontal evaporator

ABSTRACT

Disclosed herein is a once-through evaporator comprising an inlet manifold; one or more inlet headers in fluid communication with the inlet manifold; one or more tube stacks, where each tube stack comprises one or more inclined evaporator tubes; the one or more tube stacks being in fluid communication with the one or more inlet headers; where the inclined tubes are inclined at an angle of less than 90 degrees or greater than 90 degrees to a vertical; where each tube stack comprises a plurality of tubes arranged in a plurality of columns and a plurality of rows; where a plurality of tubes in a first column are offset from a plurality of tubes in a second column by a distance d2 and where a plurality of tubes in a first row are offset from a plurality of tubes in a second row by a distance d1; where d1 varies from 0.1d2 to 1000d2; one or more outlet headers in fluid communication with one or more tube stacks; and an outlet manifold in fluid communication with the one or more outlet headers.

TECHNICAL FIELD

The present disclosure relates generally to a heat recovery steam generator (HRSG), and more particularly, to a tube arrangement for controlling flow in an HRSG having inclined tubes for heat exchange.

BACKGROUND

A heat recovery steam generator (HRSG) is an energy recovery heat exchanger that recovers heat from a hot gas stream. It produces steam that can be used in a process (cogeneration) or used to drive a steam turbine (combined cycle). Heat recovery steam generators generally comprise four major components—the economizer, the evaporator, the superheater and the water preheater. In particular, natural circulation HRSG's contain evaporator heating surface, a drum, as well as the necessary piping to facilitate the appropriate circulation ratio in the evaporator tubes. A once-through HRSG replaces the natural circulation components with once-through evaporator and in doing so offers in-roads to higher plant efficiency and furthermore assists in prolonging the HRSG lifetime in the absence of a thick-walled drum.

An example of a once through evaporator heat recovery steam generator (HRSG) 100 is shown in the FIG. 1. In the FIG. 1, the HRSG comprises vertical heating surfaces in the form of a series of vertical parallel flow paths/tubes 104 and 108 (disposed between the duct walls 111) configured to absorb the required heat. In the HRSG 100, a working fluid (e.g., water) is transported to an inlet manifold 105 from a source 106. The working fluid is fed from the inlet manifold 105 to an inlet header 112 and then to a first heat exchanger 104, where it is heated by hot gases from a furnace (not shown) flowing in the horizontal direction. The hot gases heat tube sections 104 and 108 disposed between the duct walls 111. A portion of the heated working fluid is converted to a vapor and the mixture of the liquid and vaporous working fluid is transported to the outlet manifold 103 via the outlet header 113, from where it is transported to a mixer 102, where the vapor and liquid are mixed once again and distributed to a second heat exchanger 108. This separation of the vapor from the liquid working fluid is undesirable as it produces temperature gradients and efforts have to be undertaken to prevent it. To ensure that the vapor and the fluid from the heat exchanger 104 are well mixed, they are transported to a mixer 102, from which the two phase mixture (vapor and liquid) are transported to another second heat exchanger 108 where they are subjected to superheat conditions. The second heat exchanger 108 is used to overcome thermodynamic limitations. The vapor and liquid are then discharged to a collection vessel 109 from which they are then sent to a separator 110, prior to being used in power generation equipment (e.g., a turbine). The use of vertical heating surfaces thus has a number of design limitations.

Due to design considerations, it is often the case that thermal head limitations necessitate an additional heating loop in order to achieve superheated steam at the outlet. Often times additional provisions are needed to remix water/steam bubbles prior to re-entry into the second heating loop, leading to additional design considerations. In addition, there exists a gas-side temperature imbalance downstream of the heating surface as a direct result of the vertically arranged parallel tubes. These additional design considerations utilize additional engineering design and manufacturing, both of which are expensive. These additional features also necessitate periodic maintenance, which reduces time for the productive functioning of the plant and therefore result in losses in productivity. It is therefore desirable to overcome these drawbacks.

SUMMARY

Disclosed herein is a once-through evaporator comprising an inlet manifold; one or more inlet headers in fluid communication with the inlet manifold; one or more tube stacks, where each tube stack comprises one or more inclined evaporator tubes; the one or more tube stacks being in fluid communication with the one or more inlet headers; where the inclined tubes are inclined at an angle of less than 90 degrees or greater than 90 degrees to a vertical; where each tube stack comprises a plurality of tubes arranged in a plurality of columns and a plurality of rows; where a plurality of tubes in a first column are offset from a plurality of tubes in a second column by a distance d2 and where a plurality of tubes in a first row are offset from a plurality of tubes in a second row by a distance d1; where d1 varies from 0.1 d2 to 1000d2 to suit the optimal degree of heat blending; one or more outlet headers in fluid communication with one or more tube stacks; and an outlet manifold in fluid communication with the one or more outlet headers.

Disclosed herein too is a method comprising discharging a working fluid through a once-through evaporator; where the once-through evaporator comprises an inlet manifold; one or more inlet headers in fluid communication with the inlet manifold; one or more tube stacks, where each tube stack comprises one or more inclined evaporator tubes; the one or more tube stacks being in fluid communication with the one or more inlet headers; where the inclined tubes are inclined at an angle of less than 90 degrees or greater than 90 degrees to a vertical; where each tube stack comprises a plurality of tubes arranged in a plurality of columns and a plurality of rows; where a plurality of tubes in a first column are offset from a plurality of tubes in a second column by a distance d2 and where a plurality of tubes in a first row are offset from a plurality of tubes in a second row by a distance d1; where d1 varies from 0.1d2 to 1000d2 to suit the optimal degree of heat blending; one or more outlet headers in fluid communication with one or more tube stacks; and an outlet manifold in fluid communication with the one or more outlet headers; discharging a hot gas from a furnace or boiler through the once-through evaporator; and transferring heat from the hot gas to the working fluid.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the Figures, which are exemplary embodiments, and wherein the like elements are numbered alike:

FIG. 1 is a schematic view of a prior art heat recovery steam generator having vertical heat exchanger tubes;

FIG. 2 depicts a schematic view of an exemplary once-through evaporator that uses a counterflow staggered arrangement;

FIG. 3 depicts an exemplary embodiment of a once-through evaporator;

FIG. 4(A) depicts one exemplary arrangement of the tubes in a tube stack of a once-through evaporator;

FIG. 4(B) depicts an isometric view of an exemplary arrangement of the tubes in a tube stack of a once-through evaporator;

FIG. 5 depicts an end-on schematic view of a counterflow staggered arrangement of tubes in a tube stack in a once-through evaporator;

FIG. 6A is an expanded end-on view of a tube stack of the FIG. 4;

FIG. 6B is a depiction of a plane section taken within the tube stack of the FIG. 5A and depicts a staggered tube consideration;

FIG. 7A depicts an elevation end-on view of tubes that are inclined in one direction while being horizontal in another direction; the tubes are arranged in a staggered fashion;

FIG. 7B is a depiction of a plane section taken within the tube stack of the FIG. 6A and depicts a staggered tube configuration;

FIG. 8 depicts that the spacing between successive tube stacks can be varied; and

FIG. 9 depicts a once-through evaporator having 10 vertically aligned zones or sections that contain tubes through which hot gases can pass to transfer their heat to the working fluid.

DETAILED DESCRIPTION

Disclosed herein is a heat recovery steam generator (HRSG) that comprises a single heat exchanger or a plurality of heat exchangers whose tubes are arranged to be “non-vertical”. By non-vertical, it is implied the tubes are inclined at an angle to a vertical. By “inclined”, it is implied that the individual tubes are inclined at an angle less than 90 degrees or greater than 90 degrees to a vertical line drawn across a tube. In one embodiment, the tubes can be horizontal in a first direction and inclined in a second direction that is perpendicular to the first direction.

In particular, in a heat recovery steam generator, the heating surfaces—also called finned tubes—are generally horizontally disposed. In one embodiment detailed herein, the heating surfaces may be staggered as a result of which the prevailing heat transfer mode is also staggered. Such an arrangement is not limited by thermal head, no remixing of the heated fluid is generally used, nor is there a temperature gradient as depicted with the vertically disposed once through heat exchanger. The staggering may result from angular variations in the tube as shown in the FIG. 2 below.

These angular variations in the tube along with the angle of inclination are shown in the FIG. 2. The FIG. 2 shows a section of a tube that is employed in a tube stack of the once-through evaporator. The tube stack shows that the tube is inclined to the vertical in one or more directions.

While the tube in the FIG. 2 is shown to be inclined in two directions, it can be inclined in only one direction if desired. In the FIG. 2, the tube is inclined in one direction at an angle of θ1 to the vertical, while it is inclined in a second direction at an angle of θ2 to the vertical. In the FIG. 2, it may be seen that θ1 and θ2 can vary by up to 90 degrees to the vertical. If the angle of inclination θ1 and θ2 are equal to 90 degrees, then the tube is stated to be substantially horizontal. If on the other hand only one angle θ1 is 90 degrees while the other angle θ2 is less than 90 degrees or greater than 90 degrees, then the tube is said to be horizontal in one direction while being inclined in another direction. In yet another embodiment, it is possible that both θ1 and θ2 are less than 90 degrees or greater than 90 degrees, which implies that the tube is inclined in two directions. It is to be noted that by “substantially horizontal” it is implies that the tubes are oriented to be approximately horizontal (i.e., arranged to be parallel to the horizon within ±2 degrees). For tubes that are inclined, the angle of inclination θ1 and/or θ2 generally vary from about 55 degrees to about 88 degrees with the vertical. In an exemplary embodiment, it is desirable for the tube to be inclined to the vertical in at least one direction.

The section (or plurality of sections) containing the horizontal tubes is also termed a “once-through evaporator”, because when operating in subcritical conditions, the working fluid (e.g., water, ammonia, or the like) is converted into vapor gradually during a single passage through the section from an inlet header to an outlet header. Likewise, for supercritical operation, the supercritical working fluid is heated to a higher temperature during a single passage through the section from the inlet header to the outlet header.

The once-through evaporator (hereinafter “evaporator”) comprises parallel tubes that are disposed non-vertically in at least one direction that is perpendicular to the direction of flow of heated gases emanating from a furnace or boiler.

The FIGS. 3, 4(A), 4(B) and 10 depicts an exemplary embodiment of a once-through evaporator. The FIG. 3 depicts a plurality of vertical tube stacks in a once-through evaporator 200. In one embodiment, the tube stacks are aligned vertically so that each stack is either directly above, directly under, or both directly above and/or directly under another tube stack. The FIG. 4(A) depicts one exemplary arrangement of the tubes in a tube stack of a once-through evaporator; while the FIG. 4(B) depicts an isometric view of an exemplary arrangement of the tubes in a tube stack of a once-through evaporator;

The evaporator 200 comprises an inlet manifold 202, which receives a working fluid from an economizer (not shown) and transports the working fluid to a plurality of inlet headers 204(n), each of which are in fluid communication with vertical tube stacks 210(n) comprising one or more tubes that are substantially horizontal. The fluid is transmitted from the inlet headers 204(n) to the plurality of tube stacks 210(n). For purposes of simplicity, in this specification, the plurality of inlet headers 204(n), 204(n+1) . . . and 204(n+n′), depicted in the figures are collectively referred to as 204(n). Similarly the plurality of tube stacks 210(n), 210(n+1), 210(n+2) . . . and 210(n+n′) are collectively referred to as 210(n) and the plurality of outlet headers 206(n), 206(n+1), 206(n+2) and 206(n+n′) are collectively referred to as 206(n).

As can be seen in the FIG. 3, multiple tube stacks 210(n) are therefore respectively vertically aligned between a plurality of inlet headers 204(n) and outlet headers 206(n). Each tube of the tube stack 210(n) is supported in position by a plate 250 (see FIG. 4(B)). The working fluid upon traversing the tube stack 210(n) is discharged to the outlet manifold 208 from which it is discharged to the superheater. The inlet manifold 202 and the outlet manifold 208 can be horizontally disposed or vertically disposed depending upon space requirements for the once-through evaporator. From the FIGS. 3 and 4(A), it may be seen that when the vertically aligned stacks are disposed upon one another, a passage 239 is formed between the respective stacks. A baffle system 240 may be placed in these passages to prevent the by-pass of hot gases. This will be discussed later.

The hot gases from a source (e.g., a furnace, boiler or turbine) (not shown) travel perpendicular or transverse to the direction of the flow of the working fluid in the tubes 210. With reference to the FIG. 3, the hot gases travel away from the reader into the plane of the paper, or towards the reader from the plane of the paper. In one embodiment, the hot gases travel counterflow to the direction of travel of the working fluid in the tube stack. Heat is transferred from the hot gases to the working fluid to increase the temperature of the working fluid and to possibly convert some or all of the working fluid from a liquid to a vapor. Details of each of the components of the once-through evaporator are provided below.

As seen in the FIGS. 3 and/or 4(A), the inlet header comprises one or more inlet headers 204(n), 204(n+1) . . . and (204(n) (hereinafter represented generically by the term “204(n)”), each of which are in operative communication with an inlet manifold 202. In one embodiment, each of the one or more inlet headers 204(n) are in fluid communication with an inlet manifold 202. The inlet headers 204(n) are in fluid communication with a plurality of horizontal tube stacks 210(n), 210(n+1), 210(n′+2) . . . and 210(n) respectively ((hereinafter termed “tube stack” represented generically by the term “210(n)”). Each tube stack 210(n) is in fluid communication with an outlet header 206(n). The outlet header thus comprises a plurality of outlet headers 206(n), 206(n+1), 206(n+2) . . . and 206(n), each of which is in fluid communication with a tube stack 210(n), 210(n+1), 210(n+2) . . . and 210(n) and an inlet header 204(n), 204(n+1), (204(n+2) . . . and 204(n) respectively.

The terms ‘n” is an integer value, while “n′” can be an integer value or a fractional value. n′ can thus be a fractional value such as ½, ⅓, and the like. Thus for example, there can therefore be one or more fractional inlet headers, tube stacks or outlet headers. In other words, there can be one or more inlet headers and outlet headers whose size is a fraction of the other inlet headers and/or outlet headers. Similarly there can be tube stacks that contain a fractional value of the number of tubes that are contained in the other stack. It is to be noted that the valves and control systems having the reference numeral n′ do not actually exist in fractional form, but may be downsized if desired to accommodate the smaller volumes that are handled by the fractional evaporator sections. In one embodiment, there can be at least one or more fractional tube stacks in the once-through evaporator. In another embodiment, there can be at least two or more fractional tube stacks in the once-through evaporator.

In one embodiment, the once-through evaporator can comprise 2 or more inlet headers in fluid communication with 2 or more tube stacks which are in fluid communication with 2 or more outlet headers. In one embodiment, the once-through evaporator can comprise 3 or more inlet headers in fluid communication with 3 or more tube stacks which are in fluid communication with 3 or more outlet headers. In another embodiment, the once-through evaporator can comprise 5 or more inlet headers in fluid communication with 5 or more tube stacks which are in fluid communication with 5 or more outlet headers. In yet another embodiment, the once-through evaporator can comprise 10 or more inlet headers in fluid communication with 10 or more tube stacks which are in fluid communication with 10 or more outlet headers. There is no limitation to the number of tube stacks, inlet headers and outlet headers that are in fluid communication with each other and with the inlet manifold and the outlet manifold. Each tube stack is sometimes termed a bundle or a zone.

The FIG. 9 depicts another exemplary assembled once-through evaporator. The FIG. 9 shows a once-through evaporator of the FIG. 3 having 10 vertically aligned tube stacks 210(n) that contain tubes through which hot gases can pass to transfer their heat to the working fluid. The tube stacks are mounted in a frame 300 that comprises two parallel vertical support bars 302 and two horizontal support bars 304. The support bars 302 and 304 are fixedly attached or detachably attached to each other by welds, bolts, rivets, screw threads and nuts, or the like.

Disposed on an upper surface of the once-through evaporator are rods 306 that contact the plates 250. Each rod 306 supports the plate and the plates hang (i.e., they are suspended) from the rod 306. The plates 250 (as detailed above) are locked in position using clevis plates. The plates 250 also support and hold in position the respective tube stacks 210(n). In this FIG. 9, only the uppermost tube and the lowermost tube of each tube tack 210(n) is shown as part of the tube stack. The other tubes in each tube stack are omitted for the convenience of the reader and for clarity's sake.

Since each rod 306 holds or supports a plate 250, the number of rods 306 are therefore equal to the number of the plates 250. In one embodiment, the entire once-through evaporator is supported and held-up by the rods 306 that contact the horizontal rods 304. In one embodiment, the rods 306 can be tie-rods that contact each of the parallel horizontal rods 304 and support the entire weight of the tube stacks. The weight of the once-through evaporator is therefore supported by the rods 306.

Each section is mounted onto the respective plates and the respective plates are then held together by tie rods 300 at the periphery of the entire tube stack. A number of vertical plates support these horizontal heat exchangers. These plates are designed as the structural support for the module and provide support to the tubes to limit deflection. The horizontal heat exchangers are shop assembled into modules and shipped to site. The plates of the horizontal heat exchangers are connected to each other in the field.

The FIG. 5 depicts one possible arrangement of the tubes in a tube stack. The FIG. 5 is an end-on view that depicts two tube stacks that are vertically aligned. The tube stacks 210(n) and 210(n+1) are vertically disposed on one another and are separated from each other and from their neighboring tube stacks by baffles 240. The baffles 240 prevent non-uniform flow distribution and facilitate staggered and counterflow heat transfer. In one embodiment, the baffles 240 do not prevent the hot gases from entering the once-through device. They facilitate distribution of the hot gases through the tube stacks. As can be seen in the FIG. 5, each tube stack is in fluid communication with a header 204(n) and 204(n+1) respectively. The tubes are supported by metal plates 250 that have holes through which the tubes travel back and forth. The tubes are serpentine i.e., they travel back and forth between the inlet header 204(n) and the outlet header 206(n) in a serpentine manner. The working fluid is discharged from the inlet header 204(n) to the tube stack, where it receives heat from the hot gas flow that is perpendicular to the direction of the tubes in the tube stack.

The FIG. 6A is an expanded end-on view of the tube stack 210(n+1) of the FIG. 5. In the FIG. 6A, it can be seen that two tubes 262 and 264 emanate from the inlet header 204(n+1). The two tubes 262 and 264 emanate from the header 204(n+1) at each line position 260. The tubes in the FIG. 6A are inclined from the inlet header 204(n) to the outlet header 206(n), which is away from the reader into the plane of the paper.

The tubes are in a zig-zag or staggered arrangement (as can be seen in the upper left hand of the FIG. 6A), with the tube 262 traversing back and forth (in and out of the plane of the paper) in a serpentine manner between two sets of plates 250, while the tube 264 traverses back and forth (in and out of the plane of the paper) in a serpentine manner between the two sets of plates 250 in a set of holes that are in a lower row of holes from the holes through which the tube 262 travels. It is to be noted, that while this specification details two sets of plates 250, the FIG. 6A shows only one plate 250. In actuality, each tube stack may be supported by two or more sets of plates as seen previously in the FIG. 4(B). In short, the tube 262 travels through holes in the odd numbered columns (1, 3, 5, 7, . . . ) in odd numbered rows, while the tube 264 travels through even numbered columns (2, 4, 6, 8, . . . ) in even numbered rows. This produces a zig-zag looking arrangement. This zig-zag arrangement is produced because the holes in even numbered hole columns of the metal plate are off-set from the holes in the odd numbered hole columns. As a result in the zig-zag arrangement; the tubes in one row are off set or staggered vertically from the tubes in a preceding or succeeding row. With a staggered arrangement the heating circuit can lie in two flow paths so as to avoid low points in the boiler and the subsequent inability to drain pressure parts.

Specifically, shown in FIGS. 6B and 7B below are parallel water/steam circuits 1, 2, 3, 4, and so on. In the arrangements shown in the FIGS. 6B and 7B are inherent static head differential effects that need to be considered when designing the equipment. These static head differentials can lead to suboptimal flow and temperature distribution across the once-through section and hence a less than optimal design configuration. However, due to the relatively cooler exhaust gas temperature downstream of, for instance finned tubes 4 c and 3 d, there exists a cooling effect on finned tube 3 c (See FIG. 7B). This dynamic is termed “heat blending”. When this dynamic plays out across the entire heat exchanger it partially negates the static head effects and therefore the exact extent of heat blending is not necessarily optimal.

The FIG. 6B is a depiction of a plane section taken within the tube stack. The plane is perpendicular to the direction of travel of fluid in the tubes and the FIG. 6B shows the cross-sectional areas of the 7 serpentine tubes at the plane. As can be seen, the tubes (as viewed by their cross-sectional areas) are in a vertically staggered configuration. Because of the serpentine shape, the heating surface depicts the parallel tube paths in a staggered configuration that supports counterflow fluid flow and consequently counterflow heat transfer. By counterflow heat transfer it is meant that the flow in a section of a tube in one direction runs counter to the flow in another section of the same tube that is adjacent to it. The numbering shown in the FIG. 6B denotes a single water/steam circuit. For example in tube 1, the section 1 a contains fluid flowing away from the reader, while the section of tube 1 b next to it contains fluid that flows towards the reader. The different tube colors in the FIG. 6B indicates an opposed flow direction of the working fluid. The arrows show the direction of fluid flow in a single pipe.

The FIG. 7A depicts an isometric end-on view of tubes that are inclined in one direction while being horizontal in another direction. In the case of the tubes of the FIG. 7A, the tubes (i.e., 1 a, 1 b) are horizontal in a direction that is generally perpendicular to the hot gas flow, while being inclined at an angle of θ1 in a direction parallel to the hot gas flow. In one embodiment, the tube stack comprises tubes that are substantially horizontal in a direction that is parallel to a direction of flow of the hot gases and inclined in a direction that is perpendicular to the direction of flow of the hot gases as shown in the FIG. 8.

The angle θ1 can vary from 55 degrees to 88 degrees, specifically from 60 degrees to 87 degrees, and more specifically 80 degrees to 86 degrees. The inclination of the tubes in one or more directions provides unoccupied space 270 between the duct wall 280 and the rectangular geometrical shape that the tube stack would have occupied if the tubes were not inclined at all. This unoccupied space 270 may be used to house control equipment. This unoccupied space may lie at the bottom of the stack, the top of the stack or at the top and the bottom of the stack. Alternatively, this unoccupied space can be used to facilitate counterflow of the hot gases in the tube stack.

In one embodiment, this unoccupied space 270 can contain a fractional stack, i.e., a stack that is a fractional size of the regular stack 210(n) as seen in the FIGS. 4(A) and 4(B). In another embodiment, baffles can also be disposed in the unoccupied space to deflect the hot gases into the tube stack with an inline flow.

In the FIG. 7A, it may be seen that tubes are also staggered with respect to the exhaust gas flow. This is depicted in FIG. 7B, which depicts a plane section taken within the tube stack. The plane is generally perpendicular to the direction of travel of the working fluid in the tubes. As in the case of the tubes of the FIG. 6B, the fluid flow in the FIG. 7B is also in a counterflow direction. The numbering shown in the FIG. 7B denotes a single water/steam circuit. The arrows show the direction of fluid flow in a single tube. Since the tubes in the tube stack are inclined, the working fluid travels upwards from right to left. While the FIGS. 5, 6B, 7A, 7B show the hot gas flow from left to right, it can also flow in the opposite direction from right to left. If the hot gas flow is from right to left, the direction of flow in a single tube would be the opposite of that shown in the FIG. 6B.

The staggered counterflow horizontally arranged heating surface (FIG. 7B) with horizontally/inclined arranged water/steam (working fluid) circuits permits a balance between increased minimum flow and increased pressure drop from a choking device. Furthermore, the heating surface is minimized due to the staggered and counterflow heat transfer mode leading to minimal draft loss and parasitic power. However, for a given balance, this may lead to high parasitic power loss due to the flow choking requirements and/or the separator water discharge considerations, or both. This is because the pressure drop across the flow choking device can be significant as can the water discharged from the separator.

In one embodiment, the tubes in a tube stack are arranged in a plurality of columns and rows as may be seen in the FIG. 6B. The tubes of the staggered counterflow arrangement of the FIG. 6B may be arranged in a plurality of columns (Col. 1, Col. 2, Col. 3, . . . and so on). For example, the Column 1 contains tubes 1 b, 3 b, 5 b, 7 b, and so on, while the Row 1 contains tubes 1 a, 1 b, 1 c (not shown), 1 d (not shown) and so on. A first column of tubes is separated from a neighboring second column of tubes by a distance d2. The first column of tubes is separated from a third column of tubes by a distance d2+d5. In one embodiment, the distance d2 is an average distance. In another embodiment, as the distance d2 is increased, the distance d5 is reduced and vice versa. In other words, the distance between a first tube in Column 1 and an adjacent second tube in Column 2 may vary from one pair of rows to the next depending upon design considerations. The purpose of varying d1 and d2 (and consequently d4 and d5) is to optimize the extent of heat blending so as to address the coincident static head differential effects present in the design in question.

In a similar manner, a first row of tubes is separated from a neighboring second row of tubes by a distance d1. The first row of tubes is separated from a third row of tubes disposed on the opposite side of tubes from the second row of tubes by a distance of d1+d4. In other words as d1 increases, d4 decreases and vice versa. The location of the tube 2 b (relative to tube 1 b and 3 b) determines the temperature of the exhaust gas stream that contacts it. In short the ratio of d1 to d4 determines the average temperature of the exhaust gas stream that contacts the tube 2 b.

In one embodiment, the distance d1 is an average distance between the tubes in one row and the tubes in a neighboring row. In another embodiment, the distance between a first tube in Row 1 and an adjacent second tube in Row 2 may vary from one pair of columns to the next depending upon design considerations.

With regard to the arrangements shown in the FIG. 6B, it may be seen that the tubes 1 b-1 a and 2 b-2 a can operate in parallel. However, tube 2 b sees exhaust flow and temperature from both tubes 1 b and from 3 b. In other words, (with reference to the FIG. 6B) the tubes in column 2 (Col. 2) may see a large portion of a lower temperature exhaust gas stream (than the temperature of the exhaust gas stream impinging on the tube 1 b and 3 b) depending upon its location relative to the upstream tubes (1 b and 3 b) in column 1 (Col. 1). The relative position of the downstream tube 2 b to the upstream tubes 1 b and 3 b determines the temperature of the blended heat stream (from tubes 1 b and 3 b) that it (tube 2 b) encounters. In short the column of tubes located downstream of another column of tubes may see reduced temperatures. The location of the tubes in the column 2 may therefore be varied in relationship to their positions with respect to the tubes in column 1 in order to adjust the amount of heat absorbed by the tubes in the column 2. The same situation can occur in the FIG. 7B in the case of the tubes in column 2 relative to the tubes in the column 1.

The relative position of the tubes in column 2 can be adjusted relative to the position of tubes in column 1 to suit a given application. With reference once again to the FIG. 6B, it may be seen that the distance between two adjacent tubes in the 1^(st) column is d1 while the distance between adjacent tubes in the first column and the second column is d2. A triangle contacting the tube in the first column and the second column is represented by XYZ. The angle α between lines XZ and YZ may vary depending upon the lengths of d1 and d2. In an embodiment, the angle α between lines XZ and YZ may vary from 2 degrees to 88 degrees and the d1 can vary from 0.1d2 to 1000d2, preferably 0.5d2 to 500d2 and more preferably d2 to 100d2. This analysis applies to the tube configuration shown in the FIG. 7B as well.

In another embodiment depicted in the FIG. 8, with reference to the FIGS. 4A, 4B, 5, and 7A, the distance d3 between two adjacent sections 210(n) and 210(n+1) (the region occupied by the baffles 214) can be adjusted to increase or to decrease the amount of the incident exhaust gas stream from one section 210(n) impinging on another section 210(n+1). In an embodiment, the distance d3 can vary from d1 to 1000d1.

Maximum Continuous Load” denotes the rated full load conditions of the power plant.

“Once-through evaporator section” of the boiler used to convert water to steam at various percentages of maximum continuous load (MCR).

“Approximately Horizontal Tube” is a tube horizontally orientated in nature. An “Inclined Tube” is a tube in neither a horizontal position or in a vertical position, but dispose at an angle therebetween relative to the inlet header and the outlet header as shown.

It will be understood that, although the terms “first,” “second,” “third” etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, “a first element,” “component,” “region,” “layer” or “section” discussed below could be termed a second element, component, region, layer or section without departing from the teachings herein.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, singular forms like “a,” or “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” or “includes” and/or “including” when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof.

Furthermore, relative terms, such as “lower” or “bottom” and “upper” or “top,” may be used herein to describe one element's relationship to another elements as illustrated in the Figures. It will be understood that relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. For example, if the device in one of the figures is turned over, elements described as being on the “lower” side of other elements would then be oriented on “upper” sides of the other elements. The exemplary term “lower,” can therefore, encompasses both an orientation of “lower” and “upper,” depending on the particular orientation of the figure. Similarly, if the device in one of the figures is turned over, elements described as “below” or “beneath” other elements would then be oriented “above” the other elements. The exemplary terms “below” or “beneath” can, therefore, encompass both an orientation of above and below.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

Exemplary embodiments are described herein with reference to cross section illustrations that are schematic illustrations of idealized embodiments. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments described herein should not be construed as limited to the particular shapes of regions as illustrated herein but are to include deviations in shapes that result, for example, from manufacturing. For example, a region illustrated or described as flat may, typically, have rough and/or nonlinear features. Moreover, sharp angles that are illustrated may be rounded. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the precise shape of a region and are not intended to limit the scope of the present claims.

The term and/or is used herein to mean both “and” as well as “or”. For example, “A and/or B” is construed to mean A, B or A and B.

The transition term “comprising” is inclusive of the transition terms “consisting essentially of” and “consisting of” and can be interchanged for “comprising”.

While this disclosure describes exemplary embodiments, it will be understood by those skilled in the art that various changes can be made and equivalents can be substituted for elements thereof without departing from the scope of the disclosed embodiments. In addition, many modifications can be made to adapt a particular situation or material to the teachings of this disclosure without departing from the essential scope thereof. Therefore, it is intended that this disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this disclosure. 

What is claimed is:
 1. A once-through evaporator comprising: an inlet manifold; one or more inlet headers in fluid communication with the inlet manifold; one or more tube stacks, where each tube stack comprises one or more inclined evaporator tubes; the one or more tube stacks being in fluid communication with the one or more inlet headers; where the inclined tubes are inclined at an angle of less than 90 degrees or greater than 90 degrees to a vertical; where each tube stack comprises a plurality of tubes arranged in a plurality of columns and a plurality of rows; where a plurality of tubes in a first column are offset from a plurality of tubes in a second column by a distance d2 and where a plurality of tubes in a first row are offset from a plurality of tubes in a second row by a distance d1; where d1 varies from 0.1d2 to 1000d2 one or more outlet headers in fluid communication with one or more tube stacks; and an outlet manifold in fluid communication with the one or more outlet headers.
 2. The once-through evaporator of claim 1, where the distances d1 and d2 are average distances.
 3. The once through evaporator of claim 1, where the distance between successive columns can be varied.
 4. The once through evaporator of claim 1, where the distance between successive rows can be varied.
 5. The once through evaporator of claim 1, where the distance between the one or more tube stacks can be varied.
 6. The once-through evaporator of claim 1, where the tube stack comprises a tube that is substantially horizontal in a direction that is perpendicular to a direction of flow of hot gases and inclined in a direction that is parallel to the direction of flow of the hot gases.
 7. The once-through evaporator of claim 1, where the tubes in the tube stack are in a staggered arrangement; where the tubes in one row are off set from the tubes in a preceding or succeeding row.
 8. The once-through evaporator of claim 1, where the tubes in the tube stack are in a staggered arrangement, where the tubes in one row lie directly above the tubes in a succeeding row and directly below the tubes in a preceding row.
 9. The once-through evaporator of claim 1, further comprising an unoccupied space that is produced by a difference in a geometry of an inclined evaporator tube stack and a horizontal evaporator tube stack.
 10. The once-through evaporator of claim 9, wherein the unoccupied space is filled with a partial tube stack.
 11. The once-through evaporator of claim 9, where the unoccupied space contains control equipment for regulating flow of the working fluid through the tubes.
 12. The once-through evaporator of claim 1, further comprising a baffle disposed between tube stacks.
 13. The once-through evaporator of claim 1, where a tube stack straddles a baffle.
 14. The once-through evaporator of claim 1, where the tube stack comprises a tube that is substantially horizontal in a direction that is parallel to a direction of flow of hot gases and inclined in a direction that is perpendicular to the direction of flow of the hot gases.
 15. The once-through evaporator of claim 1, where the tubes in the tube stack are in an inline arrangement, where the tubes in one row lie directly above the tubes in a succeeding row and directly below the tubes in a preceding row.
 16. A method comprising: discharging a working fluid through a once-through evaporator; where the once-through evaporator comprises: an inlet manifold; one or more inlet headers in fluid communication with the inlet manifold; one or more tube stacks, where each tube stack comprises one or more inclined evaporator tubes; the one or more tube stacks being in fluid communication with the one or more inlet headers; where the inclined tubes are inclined at an angle of less than 90 degrees or greater than 90 degrees to a vertical; where each tube stack comprises a plurality of tubes arranged in a plurality of columns and a plurality of rows; where a plurality of tubes in a first column are offset from a plurality of tubes in a second column by a distance d2 and where a plurality of tubes in a first row are offset from a plurality of tubes in a second row by a distance d1; where d1 varies from 0.1d2 to 1000d2; one or more outlet headers in fluid communication with one or more tube stacks; and an outlet manifold in fluid communication with the one or more outlet headers; discharging a hot gas from a furnace or boiler through the once-through evaporator; and transferring heat from the hot gas to the working fluid. 